Yamaha XP500 2002 - Periodic Checks and Adjustments

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INTRODUCTION/PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
CHK
ADJ
NOTE:
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
D The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
D From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
D Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING ( 1,000 km)
ANNUAL
NO
.
ITEM
CHECK
OR
MAINTENANCE
JOB
1 10 20 30 40
CHECK
1 * Fuel line S Check fuel hoses and vacuum hose for cracks or damage. p p p p p
2 * Fuel filter S Check condition. p p
3 Spark plugs
S Check condition.
S Clean and regap.
p p
g
S Replace. p p
4 * Valves
S Check valve clearance.
S Adjust.
Every 40,000 km
5
Air filter element
S Clean. p p
5
Air
filter
element
S Replace. p p
6
*
V-belt case air filter
S Clean. p p
6
*
elements
S Replace. p p
7 * Front brake
S Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
p p p p p p
S Replace brake pads. Whenever worn to the limit
8 * Rear brake
S Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
p p p p p p
S Replace brake pads. Whenever worn to the limit
9
*
Brake hoses
S Check for cracks or damage. p p p p p
9
*
Brake
hoses
S Replace. (See NOTE) Every 4 years
10 * Wheels S Check runout and for damage. p p p p
11 * Tires
S Check tread depth and for damage.
S Replace if necessary.
S Check air pressure.
S Correct if necessary.
p p p p p
12 * Wheel bearings S Check bearing for looseness or damage. p p p p
13
*
Steering bearings
S Check bearing play and steering for roughness. p p p p p
13
*
Steering
bearings
S Lubricate with lithium-soap-based grease. Every 20,000 km
14 * Chassis fasteners
S Make sure that all nuts, bolts and screws are properly
tightened.
p p p p p
15 Sidestand, centerstand
S Check operation.
S Lubricate.
p p p p p
16 * Sidestand switch S Check operation. p p p p p p
17 * Front fork S Check operation and for oil leakage. p p p p
18 *
Shock absorber
assembly
S Check operation and shock absorber for oil leakage. p p p p
19 * Carburetors S Adjust engine idling speed and synchronization. p p p p p p